Fabrics for Flame Retardation

ABSTRACT

A flame-retardant fabric comprises a textile substrate having a layer of an aluminum material extending along a surface of the textile substrate and integrated with the textile substrate.

FIELD OF THE INVENTION

The present invention relates to the field of flame-resistant fabrics,and, more specifically, to enhancements for improving the flameresistance of such fabrics and the flame resistance of itemsincorporating such fabrics.

BACKGROUND OF THE INVENTION

Each year, thousands of residential fires are caused in the UnitedStates by the ignition of mattresses and bedding, resulting in hundredsof deaths and hundreds of millions of dollars in property losses.Heightened awareness of fire prevention has led to the development ofstandards and regulations directed to the reducing the likelihood thatsuch fires will occur. One approach to reducing the likelihood ofresidential fires is to use flame-resistant fabrics as flame barriers inmattresses and bedding.

SUMMARY OF THE INVENTION

A first embodiment of the present invention includes textile fibersmodified by incorporation of aluminum particles into the matrix of thefibers. In such an embodiment, the fibers may incorporate inherentlyflame-resistant polymers and/or cellulosic materials.

A second embodiment of the present invention includes methods ofincorporating aluminum particles into textile fibers. In such anembodiment, the aluminum particles may be mixed into a flowable polymeror solution of polymeric precursors, which is then extruded to form thealuminum-modified fibers.

A third embodiment of the present invention includes a woven ornon-woven textile fabric modified by application to the fabric of aflowable coating material that includes aluminum. In such an embodiment,the flowable coating material may include a latex binder and thealuminum as a suspension.

A fourth embodiment of the present invention is a coating material fortextiles that includes aluminum particles. In such an embodiment, thecoating material includes the aluminum particles and a latex binder in asuspension.

A fifth embodiment of the present invention includes a woven ornon-woven textile fabric that includes textile threads incorporatingaluminum, the fabric also having a coating that includes aluminumparticles. In such an embodiment, the fabric may be a filler cloth for amattress.

A sixth embodiment of the present invention includes an article ofmanufacture incorporating a textile fabric of the present invention. Insuch an embodiment, the article may be a mattress.

In an embodiment, a flame-retardant fabric, comprises a non-woventextile substrate consisting of cellulosic fibers and thermoplasticpolymeric fibers, the substrate having first and second filamentoussurfaces opposite each other, each of the first and second filamentoussurfaces having a plurality of the cellulosic fibers and thermoplasticpolymeric fibers projecting therefrom, and further having intersticesamong the projecting fibers of the first and second filamentoussurfaces, wherein the first filamentous surface of the substrate has afirst non-intumescent coating consisting of a solvent, a latex binderand aluminum particles and optionally a wetting agent, a surfactant anda pigment stabilizer, the first non-intumescent coating being distinctfrom the substrate and extends along the first filamentous surface andinto the interstices thereof, whereby the first non-intumescent coatingis integrated with the substrate, and the flame-retardant fabric doesnot have added flame-retardant chemistry.

In an embodiment, the second filamentous surface of the textilesubstrate has a second non-intumescent coating consisting of a solvent,a latex binder and aluminum particles and optionally a wetting agent, asurfactant and a pigment stabilizer, the second non-intumescent coatingbeing distinct from the substrate and extends along the secondfilamentous surface and into the interstices thereof, whereby the secondintumescent coating is integrated with the substrate. In an embodiment,the solvent of the first non-intumescent coating and the solvent of thesecond non-intumescent coating are each water. In an embodiment, thealuminum particles are present in the flame-retardant fabric in anamount in the range of about 0.005% to about 20% by weight of theflame-retardant fabric. In an embodiment, the aluminum particles arepresent in the flame-retardant fabric in an amount in the range of about0.005% to about 10% by weight of the flame-retardant fabric. In anembodiment, the aluminum particles are present in the flame-retardantfabric in an amount in the range of about 1% to about 5% by weight ofthe flame-retardant fabric. In an embodiment, the aluminum particles arepresent in the flame-retardant fabric in an amount in the range of about1% to about 3% by weight of the flame-retardant fabric.

In an embodiment, the fabric has a weight in the range of 2 through 8ounces per square yard. In an embodiment, the fabric has a weight in therange of about 3.4 to about 3.6 ounces per square yard. In anembodiment, the solvent is water.

In an embodiment, a method of making a flame-retardant fabric above, themethod comprising the steps of: providing the textile substrate;providing the first intumescent coating as a flowable coating materialincluding the aluminum particles in an amount in the range of about 1%to about 30% by weight of the flowable coating material; and applyingthe flowable coating material to the first surface of the textilesubstrate such that the flowable coating material forms the firstintumescent coating. In an embodiment, the applying step is performedusing a foam coating process. In an embodiment, the applying step isperformed using a spray-coating process. In an embodiment, the applyingstep is performed using a dip coating process. In an embodiment, theapplying step is performed using a slot coating process. In anembodiment, the applying step includes the step of driving off theliquid carrier from the first coating.

In an embodiment, a flame-retardant fabric comprises a non-woven textilesubstrate having cellulosic fibers and thermoplastic polymeric fibers,the substrate having first and second filamentous surfaces opposite eachother, each of the first and second filamentous surfaces having aplurality of the cellulosic fibers and thermoplastic polymeric fibersprojecting therefrom, and further having interstices among theprojecting fibers of the first and second filamentous surfaces, whereinthe first filamentous surface of the substrate has a firstnon-intumescent coating comprising a solvent, a latex binder andaluminum particles, the first non-intumescent coating being distinctfrom the substrate and extends along the first filamentous surface andinto the interstices thereof, whereby the first non-intumescent coatingis integrated with the substrate, and the flame-retardant fabric doesnot have added flame-retardant chemistry.

In an embodiment, a flame-retardant fabric, comprises a non-woventextile substrate having cellulosic fibers, the substrate having firstand second filamentous surfaces opposite each other, each of the firstand second filamentous surfaces having a plurality of the cellulosicfibers projecting therefrom, and further having interstices among theprojecting fibers of the first and second filamentous surfaces, whereinthe first filamentous surface of the substrate has a firstnon-intumescent coating comprising a solvent, a latex binder andaluminum particles, the first non-intumescent coating being distinctfrom the substrate and extends along the first filamentous surface andinto the interstices thereof, whereby the first non-intumescent coatingis integrated with the substrate, and the flame-retardant fabric doesnot have added flame-retardant chemistry.

In an embodiment, a flame-retardant fabric, comprises a non-woventextile substrate having thermoplastic polymeric fibers, the substratehaving first and second filamentous surfaces opposite each other, eachof the first and second filamentous surfaces having a plurality of thethermoplastic polymeric fibers projecting therefrom, and further havinginterstices among the projecting fibers of the first and secondfilamentous surfaces, wherein the first filamentous surface of thesubstrate has a first non-intumescent coating comprising a solvent, alatex binder and aluminum particles, the first non-intumescent coatingbeing distinct from the substrate and extends along the firstfilamentous surface and into the interstices thereof, whereby the firstnon-intumescent coating is integrated with the substrate, and theflame-retardant fabric does not have added flame-retardant chemistry.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference ismade to the following detailed description of exemplary embodimentsconsidered in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates cross-sections of aluminum-modified textile fibersaccording to an embodiment of the present invention;

FIG. 2 illustrates another cross-section of an aluminum-modified textilefiber according to the embodiment of FIG. 1;

FIG. 3 is a schematic process diagram of the burning behavior of analuminum-modified fiber of the same general type as the fiber of FIG. 1;

FIG. 4 is a schematic cross-sectional diagram of a mattress constructedin accordance with an embodiment of the present invention;

FIG. 5 is a schematic fragmentary view of a portion 5 of the mattress ofFIG. 4;

FIG. 6 is a diagrammatic depiction of an apparatus conducting a methodof manufacture of a high-loft fabric fire barrier constructed inaccordance with the present invention;

FIG. 7 is an enlarged, fragmentary cross-sectional view taken along line7-7 of FIG. 6;

FIG. 8 is a further enlarged fragmentary cross-sectional view of aportion of FIG. 7, designated by arrow 8 in FIG. 7;

FIG. 9 is a diagrammatic, fragmentary view taken in the direction ofarrow 9 in FIG. 6; and

FIG. 10 is an enlarged, fragmentary cross-sectional view taken alongline 10-10 of FIG. 6.

DETAILED DESCRIPTION OF THE DRAWINGS

An embodiment of the present invention includes textiles and textilefibers modified by incorporation of aluminum particles into the matrixof the fibers. One embodiment of the present invention includes analuminum-modified textile fiber. In such an embodiment, the textilefiber is an extruded fiber, such as viscose rayon. Referring to FIGS. 1and 2, aluminum-modified textile fibers 10 according to an embodiment ofthe present invention have aluminum particles 12 distributed throughoutthe fiber matrix 14.

In a method of making such fibers, according to an embodiment of thepresent invention, the aluminum particles may be mixed or dispersed intoa flowable polymer or solution of polymeric precursors, which is thenextruded to form the aluminum-modified fibers. Conventional extrusionmethods or modifications of conventional extrusion methods may be usedto form the fibers. In an embodiment of the present invention, theflowable polymer is cellulose of a type used to make viscose rayon. Inan exemplary embodiment, the aluminum content of the fiber is no morethan 80% w/w. In an exemplary embodiment, the aluminum content of thefiber is in the range of about 60% w/w to about 70% w/w. In an exemplaryembodiment, the fiber is a viscose rayon fiber. In an embodiment, thealuminum particles each have a particle size in a range of about 10microns to about 200 microns. In an embodiment, the aluminum particleseach have a particle size in a range of about 20 microns to about 200microns. In an embodiment, the aluminum particles each have a particlesize in a range of about 30 microns to about 200 microns. In anembodiment, the aluminum particles each have a particle size in a rangeof about 40 microns to about 200 microns. In an embodiment, the aluminumparticles each have a particle size in a range of about 50 microns toabout 200 microns. In an embodiment, the aluminum particles each have aparticle size in a range of about 100 microns to about 200 microns. Inan embodiment, the aluminum particles each have a particle size in arange of about 150 microns to about 200 microns. In an embodiment, thealuminum particles each have a particle size in a range of about 100microns to about 200 microns. In an embodiment, the aluminum particleseach have a particle size in a range of about 50 microns to about 100microns.

FIG. 3 is a schematic process diagram of the burning behavior of analuminum-modified fiber 16 according to an embodiment of the presentinvention. The fiber 16 comprises aluminum particles 18 in a cellulosicmatrix 20. As a conventional cellulosic fiber (not shown) burns, itgenerally forms a char and releases gaseous decomposition products. Whenthe aluminum-modified fiber 16 is ignited, the aluminum particles 18migrate from the degraded matrix 20 to the fiber surfaces 22, 24,forming barriers 26, 28 to mass and heat transport. The aluminum-filledbarrier 26, 28 itself is non-combustible, and provides structuralreinforcement to the charred fiber 16.

Another embodiment of the present invention includes a woven ornon-woven textile fabric modified by application of an aluminum-filledcoating material to the fabric. FIG. 4 illustrates an arrangement offabrics used in a non-flip mattress 30 in a schematic cross-sectionalview. The non-flip mattress 30 includes a non-fabric core 32, which maybe of any known type used in non-flip mattresses in general or of typesyet to be developed. The core 32 is surrounded by mattress ticking 34,which may be of any known type, and a filler cloth 36 including atextile fabric according to an embodiment of the present invention. Afabric fire barrier 38 is provided between the ticking 34 and core 32.In mattresses according to embodiments of the present invention, one orboth of the filler cloth 36 and the fabric fire barrier 38 arefire-resistant fabrics according to embodiments of the presentinvention. Further, the arrangement of fabrics in the mattress of FIG. 4and similarly-arranged mattresses according to embodiments of thepresent invention may be readily adapted to reversible mattresses (notshown) in arrangements understood in the prior art or yet to bedeveloped. Yet further, filler cloths or fabric fire barriers such asthose shown in FIGS. 4 and 5, or discussed elsewhere herein, may be usedin other household furnishings (e.g., without limitation, mattressfoundations or upholstered furniture) in arrangements known in the art.

FIG. 5 is a detail of the filler cloth 36, which is an embodiment of thefire-resistant fabric of the present invention. The filler cloth 36includes a textile substrate 40, and upper and lower coatings 42, 44,each of which extends along a respective surface of the textilesubstrate 40 and is integrated with the textile substrate 40. Inembodiments of the present invention, the upper coating 42 and/or thelower coating 44 each extends along a respective surface of the textilesubstrate 40 and is integrated with the textile substrate 40. Fillercloth 36 is an exemplary embodiment of the flame-retardant fabrics ofthe present invention, which also include fire barriers, such as firebarrier 38, and other coated flame-retardant fabrics.

In embodiments of the present invention, the textile substrate 40includes a woven or non-woven textile containing at least cellulosicfibers (not shown). The cellulosic fibers may be fire-resistantcellulosic fibers, such as fire-resistant rayon (e.g., viscose) fibers,or non-fire-resistant cellulosic fibers. Fire-resistantaluminum-modified fibers according to embodiments of the presentinvention are one of the types of fire-resistant fibers that may be usedin the fire-resistant fabric of the present invention. Other types offire-resistant fibers known in the art may also be used in thefire-resistant fabric of the present invention, including, withoutlimitation, silica-modified fibers, chemically-treated fibers, polyesterfibers, and thermoplastic polymeric fibers. In an embodiment, thetextile substrate 40 is a blend of cellulosic fibers and thermoplasticpolymeric fibers. In an embodiment, the cellulosic fibers constitutefrom about 60% to about 90% of the textile substrate 40, with thebalance of the textile substrate being thermoplastic polymer fibers. Inan embodiment, the textile substrate 40 is one of a 60/40 blend, a 65/35blend, a 70/30 blend, a 75/25 blend, an 80/20 blend, an 85/25 blend, anda 90/10 blend of cellulosic fibers/thermoplastic fibers. The selectionand manufacture of appropriate textile substrates for use in the presentinvention will be understood by those having ordinary skill in the artand possession of the present disclosure.

In embodiments of the present invention, the coatings 42, 44 are latexcoatings filled with aluminum particles 46. In other embodiments of thepresent invention (not shown), one of the upper and lower coatings 42,44 contains aluminum particles 46 and the other does not. In yet otherembodiments of the present invention, the filler cloth 36 has only anupper coating 42 or a lower coating 44.

In embodiments of the present invention, the coatings 42, 44 are appliedto the textile substrate 40 as flowable coating materials. Inembodiments of the present invention, such flowable coating materialsinclude a solvent (e.g., water), a binder (e.g., a latex binder), andaluminum particles. In some embodiments, the flowable coating materialsfurther include a pigment. In some embodiments, the flowable coatingmaterials further include auxiliary chemistries, such as wetting agents,surfactants, or pigment stabilizers. The selection and use ofappropriate solvents, binders, pigments, and auxiliary chemistries willbe understood by those having ordinary skill in the art and possessionof the present disclosure.

In embodiments of the present invention, the flowable coating materialhas a composition in which the aluminum is present in the coatingmaterial in the range of about 1% to about 30% by weight. In someembodiments, the aluminum is present in the flowable coating material inrange of about 10% to about 20% by weight. Workable flowable coatingmaterials include from about 10% to about 20% aluminum by weight in anaqueous suspension with about 5% acrylic latex as a binder. The totalsolids content of such workable coating materials is roughly 50% w/w.The foregoing amounts of aluminum, binder, and other solids may bevaried without departing from the scope and spirit of the invention, aswill be understood by those having ordinary skill in the art andpossession of the present disclosure.

Continuing to refer to FIG. 5, in embodiments of the present invention,the flowable coating material is applied to the textile substrate 40 toform the coatings 42, 44. The flowable coating material may be appliedto the textile substrate 40 by one or more of processes known in the artor yet to be developed for applying flowable materials to sheets. Suchmethods include, without limitation, dip coating processes, spraycoating processes, slot coating processes, and foam coating processes.Foam coating processes have been found to be particularly effective inapplying the coating materials of the present invention to textiles. Inan embodiment, the flowable coating material includes a liquid carrier,and the liquid carrier is driven off from the coatings 42, 44 after theflowable coating material is applied to the textile substrate.

In exemplary embodiments of the present invention, the aluminum ispresent in the filler cloth 36 in an amount of about 20% by weight ofthe filler cloth 36. In exemplary embodiments of the present invention,the aluminum is present in the filler cloth 36 in an amount in the rangeof about 0.005% about 20% by weight of the filler cloth 36. In exemplaryembodiments of the present invention, the aluminum is present in thefiller cloth 36 in an amount in the range of about 0.005% to about 10%by weight of the filler cloth 36. In exemplary embodiments of thepresent invention, the aluminum is present in the filler cloth 36 in anamount in the range of about 1% to about 3% by weight of the fillercloth 36, although, in some embodiments, the aluminum is present in thefiller cloth 36 in an amount of up to about 5% of the filler cloth 36.The amounts of coating material and/or aluminum added to the textile maybe varied without departing from the scope and spirit of the invention,as will be understood by those having ordinary skill in the art andpossession of the present disclosure. In an embodiment of the presentinvention, the coated fabric has a weight in the range of 2 ounces persquare yard to 8 ounces per square yard.

Referring now to FIGS. 6 through 10, manufacture of fire barrier 120 inaccordance with the present invention is depicted diagrammatically inFIG. 6 wherein it is seen that a blend of non-woven inherently flameretardant cellulosic fibers and thermoplastic polymeric fibers in theform of a continuous batt 140 is advanced through an apparatus 142, froma supply roll 143, into an oven 144 where the blend of fibers withinbatt 140 is bound into a high-loft fabric that emerges from the oven 144in the form of a sheet 16 that includes opposite filamentous surfaces148. As best seen in FIGS. 7 and 8, the filamentous nature of surfaces148 is a result of fibers of the batt 140 projecting from the batt 140in the form of a multitude of filaments 150, with interstices 152between the filaments 150.

Apparatus 142 includes a supply 160 of a dispersion 162 of finelydivided aluminum material dispersed within a liquid carrier, thepreferred liquid being water. The sheet 146 is passed to a station 170where dispersion 162 is applied to each surface 148 of sheet 146,preferably through respective banks 172 of spray heads 174 which directa fine mist spray 176 to each corresponding surface 148, as seen in FIG.9. The fine mist spray 176 assures that the dispersion 162 enters theinterstices 152 between the filaments 150 or sheet 146.

Upon leaving station 170, sheet 146 is directed back into oven 144 wherethe liquid carrier of the dispersion 162 within the interstices 152 isdriven off, leaving aluminum material deposited within the interstices152 to be integrated with the sheet 146, in a layer 180 of aluminummaterial extending along each surface 148 of the sheet 146, as seen inFIG. 10. The sheet 146 is then ready for dividing into appropriatelydimensioned fire barriers 38 in which layers 42, 44 of aluminum materialextend along the corresponding upper and lower surfaces of the substrate40, and are integrated with the substrate 40. The layers 42, 44 ofaluminum material provide the fire barrier 38 with lowered thermaltransmission properties as compared to previous fabric fire barriers. Inaddition, by filling the interstices with aluminum material, thefilamentous nature of the surfaces of the substrate 40 is substantiallyreduced, and preferably eliminated, producing a concomitant reduction inflame propagation across the completed fire barrier 38.

It will be seen that the present invention attains all of the objectsand advantages summarized above, namely: establishes enhanced flameretardant characteristics in high-ion fabric fire barriers constructedof non-woven inherently flame retardant fibers; provides high-loftfabric fire barriers of exceptional strength, durability and superiorflame retardant characteristics; enables the economical manufacture ofhigh-loft fabric fire barriers that exhibit exemplary performance,especially in the construction of mattresses, as well as in domesticbedding and upholstered items; utilizes inherently flame retardantfibers together with aluminum material for attaining enhanced flameretardant characteristics for exemplary flame retardant performance inthe nature of lower thermal transfer and reduced flame propagation,coupled with durability and strength, together with desirable physicalcharacteristics, without the necessity for additional coatingoperations, or otherwise adding flame retardant chemistry, in order toattain requisite flame retardant properties; simplifies the manufactureof fabric fire barriers exhibiting a high degree of flame retardantperformance, utilizing relatively simple, conventional manufacturingtechniques; provides highly reliable flame retardant performance inhigh-loft fabric fire barriers and the like, intended for rugged,long-term service; provides a mattress construction that exhibitsenhanced flame retardant characteristics; makes available a wide varietyof economical fabric fire barriers for exemplary performance over anextended service life.

Further embodiments of coated filler cloths and other coated textilefabrics according to the present invention, as well as articles ofmanufacture incorporating such coated textile fabrics, are disclosed inU.S. Pat. No. 9,469,935, which is incorporated by reference herein inits entirety.

What is claimed is:
 1. A flame-retardant fabric, comprising a non-woventextile substrate consisting of cellulosic fibers and thermoplasticpolymeric fibers, the substrate having first and second filamentoussurfaces opposite each other, each of the first and second filamentoussurfaces having a plurality of the cellulosic fibers and thermoplasticpolymeric fibers projecting therefrom, and further having intersticesamong the projecting fibers of the first and second filamentoussurfaces, wherein the first filamentous surface of the substrate has afirst non-intumescent coating consisting of a solvent, a latex binderand aluminum particles and optionally a wetting agent, a surfactant anda pigment stabilizer, the first non-intumescent coating being distinctfrom the substrate and extends along the first filamentous surface andinto the interstices thereof, whereby the first non-intumescent coatingis integrated with the substrate, and the flame-retardant fabric doesnot have added flame-retardant chemistry.
 2. The flame-retardant fabricof claim 1, wherein the second filamentous surface of the textilesubstrate has a second non-intumescent coating consisting of a solvent,a latex binder and aluminum particles and optionally a wetting agent, asurfactant and a pigment stabilizer, the second non-intumescent coatingbeing distinct from the substrate and extends along the secondfilamentous surface and into the interstices thereof, whereby the secondintumescent coating is integrated with the substrate.
 3. The flameretardant fabric of claim 2, wherein the solvent of the firstnon-intumescent coating and the solvent of the second non-intumescentcoating are each water.
 4. The flame-retardant fabric of claim 1,wherein the aluminum particles are present in the flame-retardant fabricin an amount in the range of about 0.005% to about 20% by weight of theflame-retardant fabric.
 5. The flame-retardant fabric of claim 1,wherein the aluminum particles are present in the flame-retardant fabricin an amount in the range of about 0.005% to about 10% by weight of theflame-retardant fabric.
 6. The flame-retardant fabric of claim 1,wherein the aluminum particles are present in the flame-retardant fabricin an amount in the range of about 1% to about 5% by weight of theflame-retardant fabric.
 7. The flame-retardant fabric of claim 1,wherein the aluminum particles are present in the flame-retardant fabricin an amount in the range of about 1% to about 3% by weight of theflame-retardant fabric.
 8. The flame retardant fabric of claim 1,wherein the fabric has a weight in the range of 2 through 8 ounces persquare yard.
 9. The flame retardant fabric of claim 1, wherein thefabric has a weight in the range of about 3.4 to about 3.6 ounces persquare yard.
 10. The flame retardant fabric of claim 1, wherein thesolvent is water.
 11. A method of making a flame-retardant fabric ofclaim 1, the method comprising the steps of: providing the textilesubstrate; providing the first intumescent coating as a flowable coatingmaterial including the aluminum particles in an amount in the range ofabout 1% to about 30% by weight of the flowable coating material; andapplying the flowable coating material to the first surface of thetextile substrate such that the flowable coating material forms thefirst intumescent coating.
 12. The method of claim 11, wherein theapplying step is performed using a foam coating process.
 13. The methodof claim 11, wherein the applying step is performed using aspray-coating process.
 14. The method of claim 11, wherein the applyingstep is performed using a dip coating process.
 15. The method of claim11, wherein the applying step is performed using a slot coating process.16. The method of claim 11, wherein the applying step includes the stepof driving off the liquid carrier from the first coating.
 17. Aflame-retardant fabric, comprising a non-woven textile substrate havingcellulosic fibers and thermoplastic polymeric fibers, the substratehaving first and second filamentous surfaces opposite each other, eachof the first and second filamentous surfaces having a plurality of thecellulosic fibers and thermoplastic polymeric fibers projectingtherefrom, and further having interstices among the projecting fibers ofthe first and second filamentous surfaces, wherein the first filamentoussurface of the substrate has a first non-intumescent coating comprisinga solvent, a latex binder and aluminum particles, the firstnon-intumescent coating being distinct from the substrate and extendsalong the first filamentous surface and into the interstices thereof,whereby the first non-intumescent coating is integrated with thesubstrate, and the flame-retardant fabric does not have addedflame-retardant chemistry.
 18. A method of making a flame-retardantfabric of claim 1, the method comprising the steps of: providing thetextile substrate; providing the first intumescent coating as a flowablecoating material including the aluminum particles in an amount in therange of about 1% to about 30% by weight of the flowable coatingmaterial; and applying the flowable coating material to the firstsurface of the textile substrate such that the flowable coating materialforms the first intumescent coating.
 19. A flame-retardant fabric,comprising a non-woven textile substrate having cellulosic fibers, thesubstrate having first and second filamentous surfaces opposite eachother, each of the first and second filamentous surfaces having aplurality of the cellulosic fibers projecting therefrom, and furtherhaving interstices among the projecting fibers of the first and secondfilamentous surfaces, wherein the first filamentous surface of thesubstrate has a first non-intumescent coating comprising a solvent, alatex binder and aluminum particles, the first non-intumescent coatingbeing distinct from the substrate and extends along the firstfilamentous surface and into the interstices thereof, whereby the firstnon-intumescent coating is integrated with the substrate, and theflame-retardant fabric does not have added flame-retardant chemistry.20. A flame-retardant fabric, comprising a non-woven textile substratehaving thermoplastic polymeric fibers, the substrate having first andsecond filamentous surfaces opposite each other, each of the first andsecond filamentous surfaces having a plurality of the thermoplasticpolymeric fibers projecting therefrom, and further having intersticesamong the projecting fibers of the first and second filamentoussurfaces, wherein the first filamentous surface of the substrate has afirst non-intumescent coating comprising a solvent, a latex binder andaluminum particles, the first non-intumescent coating being distinctfrom the substrate and extends along the first filamentous surface andinto the interstices thereof, whereby the first non-intumescent coatingis integrated with the substrate, and the flame-retardant fabric doesnot have added flame-retardant chemistry.